Organic Light-Emitting Display Device Mask Patterning
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Solution Overview
Problem
The patterning process for organic light-emitting display devices is complex due to the sensitivity of light-emitting layers to moisture and oxygen, requiring multiple masks for each color, which increases manufacturing costs and complexity.
Innovation Solution
A method that simplifies the mask patterning process by using a common light-emitting layer for multiple pixels, reducing the number of masks needed by forming a first light-emitting layer over all pixels, a second light-emitting layer over two specific pixels, and a third light-emitting layer over a single pixel, using only two or three masks to achieve red, green, and blue colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple patterned masks are used for each color in the light-emitting layer patterning process, then color accuracy is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The light-emitting layer is segmented into multiple sub-layers (first light-emitting layer, second light-emitting layer, third light-emitting layer), each containing specific color-emitting materials. This segmentation allows different color layers to be formed using fewer masks, as each mask can define multiple color regions simultaneously, reducing the total number of masking operations while maintaining color accuracy.
Solution Approach 2:
The patent transitions from a single-layer light-emitting structure to a multi-layer vertical structure. By stacking multiple light-emitting layers with different color materials, the system achieves full-color capability in the vertical dimension rather than requiring separate masks for each color in the horizontal plane, thereby reducing process complexity.
2Manufacturing precision
If multiple patterned masks are used for each color in the light-emitting layer patterning process, then color accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The light-emitting layer is segmented into multiple sub-layers (first light-emitting layer, second light-emitting layer, third light-emitting layer), each containing specific color-emitting materials. This segmentation allows different color layers to be formed using fewer masks, as each mask can define multiple color regions simultaneously, reducing the total number of masking operations while maintaining color accuracy.
Solution Approach 2:
The patent transitions from a single-layer light-emitting structure to a multi-layer vertical structure. By stacking multiple light-emitting layers with different color materials, the system achieves full-color capability in the vertical dimension rather than requiring separate masks for each color in the horizontal plane, thereby reducing process complexity.
3Ease of manufacture
If a single light-emitting layer is used for all pixels, then manufacturing process is simplified, but color differentiation capability is reduced
Solution Approach 1:
The light-emitting layer is segmented into multiple sub-layers (first light-emitting layer, second light-emitting layer, third light-emitting layer), each containing specific color-emitting materials. This segmentation allows different color layers to be formed using fewer masks, as each mask can define multiple color regions simultaneously, reducing the total number of masking operations while maintaining color accuracy.
Solution Approach 2:
The patent employs composite light-emitting layers where each layer contains different organic light-emitting materials that emit different colors (e.g., blue, green, red). By combining multiple layers with distinct material compositions, the system achieves full-color differentiation capability while using a unified multi-layer structure that simplifies the overall manufacturing process compared to traditional single-layer approaches.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and complexity while maintaining high color purity by minimizing the risk of misalignment and simplifying the patterning process, allowing for efficient production of full-color images with fewer masks.
Implementation Method 1
An organic light-emitting display device has a structure in which a light-emitting layer is interposed between an anode electrode and a cathode electrode, and realizes a full color image by forming the light-emitting layer to realize red, green, and blue color
Data Source
AI summary
Provided is an organic light-emitting display device that can display a full color image by forming a simple structure of light-emitting layers and a method of manufacturing the same. The organic light-emitting display device includes a substrate; a first electrode layer formed on the substrate; a second electrode layer which is formed above the first electrode layer and faces the first electrode layer; and a light-emitting layer interposed between the first electrode layer and the second electrode layer, wherein the light-emitting layer comprises first and second light-emitting layers respectively corresponding to first and second pixels having different colors from each other, and the first light-emitting layer is commonly formed in the first and second pixels, and the second light-emitting layer is formed in the second pixel.